System and method for manufacturing a vehicle trim component via concurrent compression forming and injection molding

ABSTRACT

A method of manufacturing a vehicle trim component is provided that includes disposing a fiber panel onto a first surface of a mold cavity. The method also includes compressing the fiber panel between the first surface and a second surface of the mold cavity to form the fiber panel into a desired shape. The method further includes injecting resin into the mold cavity to fill at least one void between the first surface and the second surface adjacent to the fiber panel.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of U.S.Provisional Application Ser. No. 61/528,832, entitled “SYSTEM AND METHODFOR MANUFACTURING A VEHICLE TRIM COMPONENT VIA CONCURRENT COMPRESSIONFORMING AND INJECTION MOLDING”, filed Aug. 30, 2011, which is herebyincorporated by reference in its entirety.

BACKGROUND

The invention relates generally to a system and method for manufacturinga vehicle trim component via concurrent compression forming andinjection molding.

Certain vehicle trim components are produced by compression forming afiber panel into a desired shape. For example, certain fiber panelsinclude a combination of structural fibers (e.g., natural and/orsynthetic fibers) and thermoplastic resin (e.g., polypropylene (PP),acrylonitrile butadiene styrene (ABS), polycarbonate (PC), etc.). Toform a trim component from such a fiber panel, the panel is heated toinduce the thermoplastic resin to liquefy. The fiber panel is thenplaced into a low-temperature mold, and compression molded into adesired shape. As the fiber panel cools, the thermoplastic solidifies,thereby establishing a substantially rigid composite panel. Alternativefiber panels include a combination of structural fibers and a thermosetresin (e.g., epoxy, polyester, etc.). To form a trim component from sucha fiber panel, the panel is compressed within a heated mold to form thepanel into the desired shape, and to induce curing of the resin. Oncethe thermoset resin cures, a substantially rigid composite panel isformed.

Once the molding process is complete, the composite panel is removedfrom the mold, and the edges are trimmed to the desired dimensions. Thecomposite panel is then placed within a second mold to form ancillarycomponents, such as support ribs and/or connectors. For example, thesecond mold may include a primary cavity configured to receive the trimcomponent, and secondary cavities corresponding to the shape of eachancillary component. In such configurations, liquid resin is injectedinto each of the additional cavities to form the desired ancillarycomponents. As the resin hardens, the ancillary components bond to thesurface of the composite panel, thereby forming a completed trimcomponent. Alternatively, components may be attached to the panel withadhesives and/or mechanical connectors, or rigid components may bepressed into the fiber panel during the compression forming process.

Unfortunately, the process of trimming the composite panel to establishthe dimensionally accurate edges is time consuming, and generates asignificant amount of offal (i.e., excess material). Moreover, trimmingleaves jagged edges that may weaken the composite panel, therebyreducing service life. In addition, transferring the trim component fromthe first mold to the second mold increases the duration of themanufacturing process. Furthermore, the design and manufacturing costsassociated with producing two separate molds increases the setupexpenses for the trim component manufacturing process.

BRIEF DESCRIPTION OF THE INVENTION

The present invention relates to a method of manufacturing a vehicletrim component including disposing a fiber panel onto a first surface ofa mold cavity. The method also includes compressing the fiber panelbetween the first surface and a second surface of the mold cavity toform the fiber panel into a desired shape. The method further includesinjecting resin into the mold cavity to fill at least one void betweenthe first surface and the second surface adjacent to the fiber panel.

The present invention also relates to a vehicle trim component preparedby a process including disposing a fiber panel onto a first surface of amold cavity. The process also includes compressing the fiber panelbetween the first surface and a second surface of the mold cavity toform the fiber panel into a desired shape. The process further includesinjecting resin into the mold cavity to fill at least one void betweenthe first surface and the second surface adjacent to the fiber panel.

The present invention further relates to a mold cavity for manufacturinga vehicle trim component including a first surface configured to receivea fiber panel. The mold cavity also includes a second surface configuredto compress the fiber panel between the first surface and the secondsurface to form the fiber panel into a desired shape. The mold cavityfurther includes at least one fluid pathway configured to inject resininto a void between the first surface and the second surface adjacent tothe fiber panel.

In addition, the present invention relates to a mold assembly formanufacturing a vehicle trim component. The mold assembly includes afirst mold element configured to receive a fiber panel, and aretractable pin assembly having multiple holding pins configured topenetrate the fiber panel to secure the fiber panel to the first moldelement. The mold assembly also includes a second mold elementconfigured to compress the fiber panel between a first surface of thefirst mold element and a second surface of the second mold element toform the fiber panel into a desired shape. The retractable pin assemblyis configured to withdraw the holding pins from the fiber panel prior toor during compression of the fiber panel between the first and secondsurfaces.

The present invention also relates to a mold assembly for manufacturinga vehicle trim component. The mold assembly includes a first moldelement configured to receive a fiber panel, and a second mold elementconfigured to compress the fiber panel between a first surface of thefirst mold element and a second surface of the second mold element toform the fiber panel into a desired shape. The mold assembly alsoincludes a fluid pathway configured to inject resin onto adjacent innersurfaces of a bent edge of the fiber panel such that the resin extendsto a distal end of the bent edge.

The present invention further relates to a mold assembly formanufacturing a vehicle trim component. The mold assembly includes afirst mold element and a second mold element configured to be broughttogether to compress a fiber panel into a desired shape. The moldassembly also includes a trim blade configured to penetrate the fiberpanel as the first and second mold elements are brought together to trimthe fiber panel to desired dimensions. In addition, the mold assemblyincludes a floating core assembly coupled to the second mold element,and configured to urge the fiber panel against a surface of the firstmold element before the trim blade penetrates the fiber panel.

DRAWINGS

FIG. 1 is a perspective view of an exemplary vehicle that may include atrim component manufactured by a concurrent compression forming andinjection molding process.

FIG. 2 is a perspective view of a part of the interior of the vehicle ofFIG. 1.

FIG. 3 is a perspective view of an embodiment of a molding assemblyconfigured to produce a trim component via concurrent compressionforming and injection molding.

FIG. 4 is a cross-sectional view of an embodiment of a molding assemblyin a closed position.

FIG. 5 is a front view of an embodiment of a vehicle trim componentmanufactured by concurrent compression forming and injection molding.

FIG. 6 is a perspective view of an embodiment of a vehicle trimcomponent manufactured by concurrent compression forming and injectionmolding, showing the process of applying a cover stock.

FIG. 7 is a front view of an embodiment of a vehicle trim componentmanufactured by concurrent compression forming and injection molding,including a weakened zone configured to facilitate airbag deployment.

FIG. 8 is a cross-sectional view of an embodiment of a vehicle trimcomponent manufactured by concurrent compression forming and injectionmolding, including a reinforcement element extending through a fiberpanel.

FIG. 9 is a cross-sectional view of an embodiment of a vehicle trimcomponent manufactured by concurrent compression forming and injectionmolding, including a high curvature element formed within a gap in afiber panel.

FIG. 10 is a cross-sectional view of an embodiment of a vehicle trimcomponent manufactured by concurrent compression forming and injectionmolding, including a lap joint between a resin component and a fiberpanel.

FIG. 11 is a flow diagram of an exemplary method of manufacturing avehicle trim component via concurrent compression forming and injectionmolding.

FIG. 12 is a schematic diagram of an embodiment of a mold assemblyhaving a retractable pin assembly configured to secure a fiber panelwithin a mold cavity.

FIG. 13 is a schematic diagram of the mold assembly of FIG. 12, in whichthe fiber panel is secured to a mold element of the mold assembly viaholding pins.

FIG. 14 is a schematic diagram of the mold assembly of FIG. 12, in whichthe holding pins are retracted.

FIG. 15 is a schematic diagram of an embodiment of a mold assemblyhaving a fluid pathway configured to inject resin into a void formed bya holding pin.

FIG. 16 is a schematic diagram of the mold assembly of FIG. 15, in whicha fiber panel is secured to a mold element of the mold assembly via aholding pin.

FIG. 17 is a schematic diagram of the mold assembly of FIG. 15, in whichthe holding pin is retracted.

FIG. 18 is a schematic diagram of the mold assembly of FIG. 15, in whichresin is injected into the void formed by the holding pin.

FIG. 19 is a top view of an embodiment of a vehicle trim componentformed within a mold cavity having a retractable pin assembly.

FIG. 20 is a flow diagram of an embodiment of a method for forming avehicle trim component within a mold assembly having a retractable pinassembly.

FIG. 21 is a schematic diagram of an embodiment of a mold assemblyhaving a fluid pathway configured to inject resin onto adjacent innersurfaces of a bent edge of a fiber panel.

FIG. 22 is a schematic diagram of the mold assembly of FIG. 21 in aclosed position.

FIG. 23 is a cross-sectional view of an embodiment of a vehicle trimcomponent having a resin feature configured to support a bent edge of afiber panel.

FIG. 24 is a flow diagram of an embodiment of a method for forming avehicle trim component by injecting resin onto adjacent inner surfacesof a bent edge of a fiber panel.

FIG. 25 is a schematic diagram of an embodiment of a mold assemblyhaving a floating core assembly configured to urge a fiber panel againsta surface of a mold element.

FIG. 26 is a schematic diagram of the mold assembly of FIG. 25, in whicha core of the floating core assembly is in an extended position, and thefiber panel is disposed against the surface of the mold element.

FIG. 27 is a schematic diagram of the mold assembly of FIG. 25, in whichthe core of the floating core assembly is in a retracted position.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of an exemplary vehicle 10 that may includea trim component manufactured by a concurrent compression forming andinjection molding process. As illustrated, the vehicle 10 includes aninterior 12 having a seat 14, an armrest 16 and a center console 18. Asdiscussed in detail below, certain trim components of the seat 14, thearmrest 16, the center console 18 and/or other areas within the interior12 may be manufactured by a concurrent compression forming and injectionmolding process. For example, in certain embodiments, a vehicle trimcomponent is prepared by a process including disposing a fiber panelonto a first surface of a mold cavity, and compressing the fiber panelbetween the first surface and a second surface of the mold cavity toform the fiber panel into a desired shape. Resin is then injected intothe mold cavity to fill a void between the first surface and the secondsurface adjacent to the fiber panel. In certain embodiments, the voidextends about a periphery of the fiber panel. In such embodiments, theinjected resin will fill the void, and establish a border about thefiber panel as the resin hardens and/or cures. Due to the dimensionalaccuracy of the mold cavity, each edge of the resultant trim componentwill substantially correspond to the desired dimensions. As a result,the process of trimming the edges of the component after formation maybe obviated, thereby decreasing the duration of the manufacturingprocess, and reducing the quantity of offal that may otherwise bedeposited in a landfill.

In certain embodiments, resin is also injected into at least onesecondary void between the fiber panel and the second surface to form anancillary component of the vehicle trim component. For example, the moldcavity may include multiple secondary voids configured to establish ribsalong a surface of the fiber panel. The ribs are configured to supportthe fiber panel, thereby providing a stronger component, and/or reducingthe weight of the component by facilitating a reduction in fiber panelthickness. Because the fiber panel and the ancillary components areformed within a single mold cavity, the process of transferring the partbetween a compression mold and an injection mold is obviated, therebyreducing the duration of the manufacturing process. In addition,employing a single mold reduces design and manufacturing costs, ascompared to producing a first mold for the compression forming processand a second mold for the injection molding process.

FIG. 2 is a perspective view of a part of the interior of the vehicle ofFIG. 1. As illustrated, the vehicle interior 12 includes variouselements, such as the illustrated center console 18, floor console 20,interior door panel 22, instrument panel 24, headliner 26, overheadconsole 28 and sun visor 30. As discussed in detail below, each elementof the vehicle interior 12 may include one or more trim componentsmanufactured by a combination of compression forming and injectionmolding. The concurrent compression forming and injection moldingprocess may facilitate formation of a trim component havingdimensionally accurate edges, thereby obviating the post-moldingtrimming process. In addition, by forming the fiber panel and moldingcertain ancillary components within a single mold cavity, the during ofthe manufacturing process may be substantially reduced, as compared toprocesses that include a first compression mold and a second injectionmold.

FIG. 3 is a perspective view of an embodiment of a molding assembly 32configured to produce a trim component via concurrent compressionforming and injection molding. In the illustrated embodiment, themolding assembly 32 includes a first (e.g., lower) mold element 34, anda second (e.g., upper) mold element 36. As illustrated, the first moldelement 34 includes a first surface 38 defining a first portion of amold cavity 40, and the second mold element 36 includes a second surface42 defining a second portion of the mold cavity 40. As discussed indetail below, the first surface 38 is configured to receive a fiberpanel 44, and the second surface 42 is configured to compress the fiberpanel 44 against the first surface 38 to form the fiber panel 44 into adesired shape.

In certain embodiments, the fiber panel 44 includes a combination ofstructural fibers and thermoplastic resin. The structural fibers mayinclude natural fibers, such as hemp, wood, flax, kenaf and sisal,and/or synthetic fibers, such as glass fibers, carbon fibers andpolymeric fibers. In addition, the thermoplastic resin may includepolypropylene (PP), acrylonitrile butadiene styrene (ABS) and/orpolycarbonate (PC) binders, for example. By way of example, the fiberpanel 44 may be constructed from about 50 percent natural fibers andabout 50 percent PP. To facilitate compression forming, the fiber panel44 is heated (e.g., to about 200 degrees Celsius) to induce thethermoplastic resin to liquefy. The fiber panel 44 is then disposed ontothe first surface 38 of the cavity 40, and compressed between the firstsurface 38 and the second surface 42 as the second mold element 36 isdriven toward the first mold element 34 along the direction 46. As thefiber panel 44 cools within the mold assembly 32, the thermoplasticsolidifies, thereby establishing a substantially rigid composite panelthat conforms to the shape of the mold cavity 40.

In further embodiments, the fiber panel 44 includes a combination ofstructural fibers and a thermoset resin. Similar to the embodimentdescribed above, the structural fibers may include natural fibers, suchas hemp, wood, flax, kenaf and sisal, and/or synthetic fibers, such asglass fibers, carbon fibers and polymeric fibers. In addition, thethermoset resin may include epoxy resin, polyimide resin, polyesterresin and/or vinylester resin, for example. By way of example, the fiberpanel 44 may be constructed from Fibrowood, which is manufactured byJohnson Controls Technology Company of Holland, Mich. To facilitatecompression forming, the fiber panel 44 is disposed onto the firstsurface 38 of the cavity 40, and compressed between the first surface 38and the second surface 42 as the second mold element 36 is driven towardthe first mold element 34 along the direction 46. During the compressionprocess, the panel 44 is heated (e.g., via a heated mold assembly 32),thereby inducing the thermoset resin to cure. Consequently, asubstantially rigid composite panel that conforms to the shape of themold cavity 40 is formed.

After the fiber panel 44 is compressed between the first surface 38 andthe second surface 42, resin is injected into the mold cavity (e.g., viathe port 48) to fill at least one void between the first surface 38 andthe second surface 42 adjacent to the fiber panel 44. For example, incertain embodiments, the void extends about a periphery 50 of the fiberpanel 44. In such embodiments, the injected resin will fill the void,and establish a border about the fiber panel 44 as the resin hardensand/or cures. Due to the dimensional accuracy of the mold cavity, eachedge of the resultant trim component will substantially correspond tothe desired dimensions. As a result, the process of trimming the edgesof the component after formation may be obviated, thereby decreasing theduration of the manufacturing process, and reducing the quantity ofoffal that may otherwise be deposited in a landfill.

In further embodiments, the void corresponds to a gap 52 within thefiber panel 44. In such embodiments, the resin will fill the gap,thereby establishing a substantially continuous structure. For example,the gap 52 may be configured to establish a weakened zone extendingalong the interface between the fiber panel 44 and the molded resinwithin the gap 52. As discussed in detail below, the weakened zone maybe configured to facilitate separation of the molded resin from thefiber panel 44, thereby enabling deployment of an airbag, for example.In further embodiments, the resin may fill gaps 52 formed byunintentional tearing of the fiber panel 44 during the compressionforming process, thereby forming a trim component having a substantiallycontinuous surface. In addition, the gap 52 may be configured toestablish a high curvature region of the trim component. For example,the mold cavity 40 may be contoured to form the fiber panel into a shapehaving a relatively low curvature, and to form the resin into an elementhaving a high curvature. In this manner, a trim component having adesired shape and structural properties may be formed. While the fiberpanel 44 includes a single gap 52 in the illustrated embodiment, itshould be appreciated that alternative fiber panels 44 may includeadditional gaps to establish weakened zones, to fill torn areas of thefiber panel and/or to form high curvature regions of the trim component,for example.

FIG. 4 is a cross-sectional view of an embodiment of a molding assembly32 in a closed position. In the illustrated embodiment, the mold cavity40 includes a void 54 extending about the periphery 50 of the fiberpanel 44. As previously discussed, resin may be injected into the void54 to establish a border about the fiber panel 44 as the resin hardensand/or cures. In the illustrated embodiment, the molding assembly 32includes a first fluid pathway 56 extending between the port 48 and afirst portion of the void 54, and a second fluid pathway 58 extendingbetween the port 48 and a second portion of the void 54. In thisconfiguration, when liquid resin is injected into the port 48, the resinwill flow into the void 54, thereby establishing a border surroundingthe fiber panel 44. The molding assembly 32 also includes a third fluidpathway 60 extending between the port 48 and the gap 52, therebyfacilitating resin flow to the gap 52.

In the illustrated embodiment, the mold cavity 40 includes a secondaryvoid 62 positioned between the fiber panel 44 and the second surface 42of the mold cavity 40. The secondary void 62 is configured to form anancillary component of the vehicle trim component, such as a support ribor a connector, for example. As illustrated, a fourth fluid pathway 64extends between the port 48 and the second void 62. In thisconfiguration, when liquid resin is injected into the port 48, the resinwill flow into the void 62, thereby establishing the ancillary componentas the resin cures and/or hardens.

In operation, a fiber panel 44 is disposed onto the first surface 38 ofthe mold cavity 40, and the fiber panel 44 is compressed between thefirst surface 38 and the second surface 42 of the mold cavity 40 to formthe fiber panel 44 into the desired shape. As the fiber panel 44solidifies within the mold cavity 40, resin is injected into the port48, thereby filling the voids 52, 54 and 62. As the resin cures andhardens, the resin binds to the fiber panel 44, thereby forming a trimcomponent having the desired shape, structural properties and/orancillary components. In certain embodiments, the resin may include athermoplastic material, such as polypropylene (PP), acrylonitrilebutadiene styrene (ABS) or polycarbonate (PC), or a thermoset material,such as epoxy resin, polyimide resin, polyester resin or vinylesterresin. In such embodiments, the resin is injected into the mold in aliquid state, and solidifies as the resin cures/hardens. As a result,resin parts are formed having shapes corresponding to the shapes of therespective voids within the mold cavity 40. In certain embodiments, theinjected resin may be molded with a cellular structure (e.g., via achemical or mechanical blowing agent), to reduce a mass of the trimcomponent and/or to enhance processing properties.

FIG. 5 is a front view of an embodiment of a vehicle trim component 66manufactured by concurrent compression forming and injection molding. Asillustrated, the trim component 66 includes a fiber panel 44, and aresin border 68 disposed about the periphery 50 of the fiber panel 44.As previously discussed, the dimensional accuracy of the mold cavity 40facilitates formation of a resin border 68 having desired dimensions,thereby obviating the post-formation panel trimming process. Forexample, to form a trim component 66 having a width 70 and a length 72,the fiber panel 44 is trimmed to a width 74 smaller than the desiredwidth 70, and to a length 76 smaller than the desired length 72. Thefiber panel 44 is then placed within a mold cavity 40 having the desireddimensions (i.e., a width 70 and a height 72). After the panel 44 iscompressed between the first surface 38 and the second surface 42, resinis injected into the void 54 surrounding the periphery 50, therebyforming the border 68, and establishing a trim component 66 having thedesired dimensions.

Because the fiber panel 44 is trimmed prior to the compression formingprocess, the offal (i.e., excess material) may be recycled. In contrast,recycling post-formation offal may be more difficult because thethermoset resin within the fiber panel has cured/hardened, and/or thethermoplastic resin has bonded to the structural fibers. In addition,because the resin fills the void between the periphery 50 of the fiberpanel 44 and the edges of the mold cavity 40, the edges of the trimcomponent 66 may be dimensionally accurate despite variations in thefiber panel edges. Consequently, the edges of the fiber panel may betrimmed to rough dimensions prior to the compression forming process,thereby substantially reducing the duration associated with fiber paneltrimming.

In the illustrated embodiment, the trim component 66 includes a resinfeature 78 formed within the gap 52 of the fiber panel. As illustrated,the feature 78 includes an opening 80 having dimensionally accurateedges. To form the opening 80, the mold cavity 40 includes a protrusionhaving the shape of the opening 80. As resin is injected into the gap52, the protrusion blocks the flow of resin to the opening 80, therebyestablishing the desired feature 78. As will be appreciated, the feature78 may be utilized to secure other components to the trim component 66,and/or to secure the trim component 66 to the vehicle interior 12.Furthermore, while a substantially hexagonal opening 80 is employedwithin the illustrated embodiment, it should be appreciated thatalternative embodiments may include other opening configurations (e.g.,square, circular, elliptical, etc.). In addition, it should beappreciated that further embodiments may include additional features 78distributed throughout the fiber panel 44. Because the feature 78 isformed during the concurrent compression forming/injection moldingprocess, the practice of applying a feature to the fiber panel afterformation is obviated. As a result, the duration and expense associatedwith trim component manufacturing may be substantially reduced.

The illustrated trim component 66 also includes ancillary componentscoupled to the surface of the fiber panel 44. As previously discussed,such ancillary components may be formed by injecting resin into asecondary void between the fiber panel and the second surface of themold cavity. In the illustrated embodiment, the ancillary componentsinclude ribs 82, and connectors 84. However, it should be appreciatedthat alternative embodiments may include other ancillary components,such as pins, mounts, etc. The connectors 84 are configured tofacilitate coupling between the trim component 66 and another surface(e.g., door frame, instrument panel support structure, etc.) within theinterior 12 of the vehicle 10. The ribs 82 are configured to support thefiber panel 44, thereby providing a stronger trim component, and/orreducing the weight of the trim component by facilitating a reduction infiber panel thickness. In certain embodiments, the ribs 82 may extendacross the interface between the fiber panel 44 and the border 68,and/or across the interface between the fiber panel 44 and the resinfeature 78. In such embodiments, the ribs 82 may enhance the strength ofthe panel/border interface and/or the panel/feature interface. Becausethe fiber panel and the ancillary components are formed within a singlemold cavity, the process of transferring the part between a compressionmold and an injection mold is obviated, thereby reducing the duration ofthe manufacturing process. In addition, employing a single mold reducesdesign and manufacturing costs, as compared to producing a first moldfor the compression forming process and a second mold for the injectionmolding process.

FIG. 6 is a perspective view of an embodiment of a vehicle trimcomponent 66 manufactured by concurrent compression forming andinjection molding, showing the process of applying a cover stock 86. Asillustrated, the cover stock 86 is applied to the fiber panel 44 (e.g.,via an adhesive layer) to form a show surface 88. The cover stock 86 maybe a woven or non-woven fabric, an appliqué, a vinyl layer, a foamlayer, a foil layer, or a leather covering, for example. Such a coverstock 86 may establish a show surface 88 that matches the vehicleinterior 12, thereby enhancing the appearance of the trim component 66.In the illustrated embodiment, the cover stock 86 is applied to thefiber panel 44 after the trim component 66 is formed. However, incertain embodiments, the cover stock may be applied during thecompression molding process. For example, the cover stock may bepositioned between the first surface 38 of the mold cavity 40 and thefiber panel 44 prior to compression forming. As the fiber panel 44solidifies within the mold cavity 40, the cover stock may bind to thefiber panel, thereby establishing a desired show surface. As will beappreciated, the cover stock 86 may be applied to at least a portion ofthe fiber panel 44 and/or at least a portion of a resin component toprovide the desired show surface 88.

FIG. 7 is a front view of an embodiment of a vehicle trim componentmanufactured by concurrent compression forming and injection molding,including a weakened zone configured to facilitate airbag deployment. Inthe illustrated embodiment, the trim component 66 includes a resinfeature 90 formed within the gap 52 of the fiber panel 44. Asillustrated, the resin feature 90 is substantially H-shaped, therebyestablishing a long interface between the feature 90 and the fiber panel44. The long interface provides a weakened zone, in which a sufficientforce applied to the trim component 66 will induce separation of theresin feature 90 from the fiber panel 44. By way of example, the trimcomponent 66 may be an interior door panel configured to conceal anairbag. Upon deployment, the airbag will apply a force to the trimcomponent 66 sufficient to induce separation of the resin feature 90from the fiber panel 44, thereby facilitating airbag deployment.

While the feature 90 is substantially H-shaped in the illustratedembodiment, it should be appreciated that alternative embodiments mayinclude other weakened zone shapes (e.g., U-shaped, T-shaped, circular,square, etc.). In addition, certain trim components 66 may include asubstantially continuous fiber panel 44 surrounded by a resin border 68,thereby forming a weakened zone about the periphery 50 of the fiberpanel 44. Moreover, it should be appreciated that the trim component mayinclude various reinforcing features (e.g., ribs 82, additional fiberpanels, thicker resin regions, etc.) configured to particularly adjustthe strength of the weakened zone such that the trim component remainssubstantially intact until the airbag is deployed. Furthermore, theweakened zone between the resin feature 90 and the fiber panel 44 may befurther weakened by scoring (e.g., via in-mold scoring, laser scoring,etc.), thereby ensuring that the force of the airbag induces the resinfeature 90 to separate from the fiber panel 44.

In certain embodiments, additional elements may be utilized to reinforcethe weakened zone and/or to tether components during airbag deployment.For example, after the trim component 66 is formed, a flexible panel(e.g., carbon fiber, glass fiber, synthetic fiber, etc.) may be coupledto the fiber panel 44 and to the resin feature 90. In such embodiments,during airbag deployment, the flexible panel may tether the resinfeature 90 to the fiber panel 44, thereby retaining the resin feature 90as the resin feature 90 separates from the fiber panel 44 at theweakened zone. In further embodiments, the flexible panel may be coupledto the trim component 66 during the compression forming/injectionmolding process. For example, the flexible panel may be placed in themold cavity adjacent to the fiber panel. As the fiber panel 44solidifies within the mold cavity, the flexible panel will bond to thefiber panel. In addition, resin injected into the gap will bond to theflexible panel, thereby establishing a trim component configured toretain the resin feature 90 during airbag deployment.

FIG. 8 is a cross-sectional view of an embodiment of a vehicle trimcomponent manufactured by concurrent compression forming and injectionmolding, including a reinforcement element 92 extending through thefiber panel 44. As illustrated, the fiber panel 44 includes a gap 52that enables resin to flow through the fiber panel 44 during theinjection molding process. Consequently, portions of the resinreinforcement element 92 are formed on each side of the fiber panel 44,thereby locking the element 92 to the panel 44. Due to the thickness ofthe reinforcement element 92, the resin component may provide additionalstructural rigidity to a region of the trim component that mayexperience high loading. By combining various resin and fiber elements,a trim component 66 having a desired shape and a desired strength may beformed.

In certain embodiments, the reinforcement element 92 is formed bycompressing the fiber panel 44 between opposite surfaces of the moldcavity. Once the fiber panel solidifies, at least one of the surfaces ispartially retracted, thereby establishing a void having the shape of thereinforcement element 92. Resin is then injected into the void to formthe element 92. In alternative embodiments, the shape of the fiber panel44 adjacent to the gap 52 is formed by the pressure of the injectedresin. Such embodiments may obviate the step of retracting the moldsurface after the compression molding process.

FIG. 9 is a cross-sectional view of an embodiment of a vehicle trimcomponent manufactured by concurrent compression forming and injectionmolding, including a high curvature element 94 formed within a gap 52 inthe fiber panel 44. By way of example, the mold cavity 40 may becontoured to form the fiber panel into a shape having a relatively lowcurvature, and to form the resin into a resin element 94 having a highcurvature. Because the curvature of the fiber panel may be limited dueto the rigidity of the fibers, forming the trim component 66 in thismanner facilitates formation of high curvatures regions, while maintaina desired structural rigidity. As previously discussed, the gap 52 inthe fiber panel 44 may be intentionally positioned within a highcurvature region and/or unintentionally formed by fiber tearing withinthe high curvature region.

FIG. 10 is a cross-sectional view of an embodiment of a vehicle trimcomponent manufactured by concurrent compression forming and injectionmolding, including a lap joint between a resin component and a fiberpanel. As illustrated, a resin component 96 overlaps a portion of thefiber panel 44, thereby forming a lap joint 98. By increasing thecontact area between the resin component 96 and the fiber panel 44, thestructural integrity of the interface may be enhanced. As will beappreciated, the extend of the overlap may be particularly configured toestablish the desired bonding strength between the resin component 96and the fiber panel 44. It should also be appreciated, that inalternative embodiments, the fiber panel 44 may overlap a portion of theresin component 96.

FIG. 11 is a flow diagram of an exemplary method 100 of manufacturing avehicle trim component via concurrent compression forming and injectionmolding. First, as represented by block 102, at least one edge of afiber panel is trimmed to a desired dimension. As previously discussed,trimming the fiber panel prior to the compression forming processfacilitates recycling of the offal, thereby reducing waste that mayotherwise be deposited in a landfill. Once the fiber panel is trimmed,the panel is heated, as represented by block 104. For example, if thefiber panel includes thermoplastic resin, heating the panel will liquefythe resin, thereby facilitating compression forming of the panel.Alternatively, if the fiber panel includes a thermoset resin, the stepof heating the fiber panel prior to placing the panel into the moldcavity may be obviated.

The fiber panel is then disposed onto a first surface of a mold cavity,as represented by block 106. Next, the fiber panel is compressed betweenthe first surface and a second surface of the mold cavity to form thefiber panel into a desired shape, as represented by block 108. Resin isthen injected into the mold cavity to fill at least one void between thefirst surface and the second surface adjacent to the fiber panel, asrepresented by block 110. For example, the resin may fill a voidextending about a portion of the periphery of the fiber panel to form aborder. The resin may also fill a void corresponding to a gap within thefiber panel, thereby providing a substantially continuous structure. Incertain embodiments, the resin is injected into the mold cavity to fillat least one secondary void between the fiber panel and the secondsurface, as represented by block 112. For example, the secondary voidmay be shaped to form an ancillary component, such as a supporting ribor a connector. As will be appreciated, steps 110 and 112 may beperformed at the same time by injecting resin into a port that isfluidly coupled to the primary and secondary voids. After the interiortrim component is removed from the mold cavity, a cover stock may bedisposed onto the vehicle trim component, as represented by block 114.

In certain embodiments, the fiber panel 44 and/or various resincomponents may be particularly configured to provide a desirable showsurface for the trim component 66. In such embodiments, the cover stock86 may be obviated, thereby reducing manufacturing costs. In addition,while a single fiber panel 44 is described above, it should beappreciated that the mold cavity may be configured to receive multiplefiber panels, and to compression mold the fiber panels into a desiredtrim component 66. Furthermore, in certain embodiments, multiple resins(e.g., shots of resin) may be injected into the mold cavity to formresin components having varying aesthetic and/or structural properties.For example, glass-filled resin may be injected into regions whereadditional structural support is desired, and pure resin may be injectedinto regions which form a portion of the show surface. In addition,harder and/or softer resins may be injected into various regions toprovide the desired texture/structural properties.

In certain embodiments, resin may be injected through a first fluidpathway extending to the first surface of the mold cavity, and through asecond fluid pathway extending to the second surface of the mold cavity.In such embodiments, a portion of each side of the fiber panel may becoated with a layer of resin. In alternative embodiments, resin may beinjected through a fluid pathway extending through one surface of themold cavity. The resin may then flow through a gap in the fiber panel,thereby enabling the resin to coat at least a portion of each side ofthe fiber panel. In further embodiments, the pressure of the injectedresin may induce the formation of a gap that facilitates resin flowthrough the fiber panel 44.

Furthermore, certain components of an airbag assembly may be formed bythe concurrent compression forming/injection molding process. Forexample, in certain embodiments, an airbag door may include a first halfformed by a compression formed fiber panel, and a second half formed byan injection molded resin. The airbag door may be configured to separatealong the interface between the fiber panel and the resin component. Infurther embodiments, the mold cavity may include a void configured toform an injection molded airbag chute adjacent to the airbag door. Inaddition, additional components, such as hinges, reinforcement elementsand/or tethers, may be placed into the mold cavity prior to thecompression forming/injection molding process. Such components may beintegrated into the airbag door as the fiber panel is compressed and/orthe resin is injection.

In certain embodiments, the trim component 66 may include structurallyweakened and/or strengthened regions to provide a desired rigidityand/or to absorb energy associated with an impact. For example, thefiber panel 44 may include scores, seams and/or perforations to enablethe fiber panel 44 to collapse during an impact, thereby absorbing aportion of the impact energy. In addition, resin ribs coupled to thefiber panel may be arranged (e.g., oriented perpendicular to a desiredcollapse direction) to facilitate a desired degree of energy absorption.In certain embodiments, the scores, seams and/or perforations may befilled with resin to provide a desirable show surface, while enablingthe trim component to collapse during an impact.

Retractable Pin Assembly for Securing Fiber Panel to Mold

Certain mold assemblies include a first mold element configured toreceive a fiber panel, and multiple pins configured to penetrate thefiber panel to secure the fiber panel to the first mold element. Thepins hold the fiber panel in a desired position and/or orientation,thereby enabling a second mold element to compress the fiber panelagainst the first mold element to form a component of a desired shape.Unfortunately, the pins may leave irregular voids in the fiber panel,thereby establishing a component having an uneven texture. In addition,the second mold element may include recesses configured to accommodatethe pins extending from the first mold element. Forming the recesseswithin the second mold element may increase the cost and complexity ofthe mold assembly.

Certain embodiments of the mold assembly described below include aretractable pin assembly configured to retract holding pins prior to orduring compression of the fiber panel, thereby enabling resin to fillvoids formed by the holding pins. As a result, the component may have asubstantially smooth texture. For example, in certain embodiments, amold assembly for manufacturing a vehicle trim component includes afirst mold element configured to receive a fiber panel. The moldassembly also includes a retractable pin assembly having multipleholding pins configured to penetrate the fiber panel to secure the fiberpanel to the first mold element. In addition, the mold assembly includesa second mold element configured to compress the fiber panel between afirst surface of the first mold element and a second surface of thesecond mold element to form the fiber panel into a desired shape. Theretractable pin assembly is configured to withdraw the holding pins fromthe fiber panel prior to or during compression of the fiber panelbetween the first and second surfaces. Furthermore, the mold assemblymay include fluid pathways configured to inject resin into voids in thefiber panel formed by the holding pins. Consequently, a substantiallysmooth component may be formed when the resin cures and hardens.

FIG. 12 is a schematic diagram of an embodiment of a mold assembly 116having a retractable pin assembly configured to secure a fiber panelwithin a mold cavity. In the illustrated embodiment, the mold assembly116 includes a first (e.g., upper) mold element 118 and a second (e.g.,lower) mold element 120. As illustrated, the first mold element 118includes a first surface 122 defining a first portion of a mold cavity124, and the second mold element 120 includes a second surface 126defining a second portion of the mold cavity 124. The first surface 122is configured to receive a fiber panel 128, and the second surface 126is configured to compress the fiber panel 128 against the first surface122 to form the fiber panel 128 into a desired shape.

In certain embodiments, the fiber panel 128 includes a combination ofstructural fibers and thermoplastic resin. The structural fibers mayinclude natural fibers, such as hemp, wood, flax, kenaf and sisal,and/or synthetic fibers, such as glass fibers, carbon fibers andpolymeric fibers. In addition, the thermoplastic resin may includepolypropylene (PP), acrylonitrile butadiene styrene (ABS) and/orpolycarbonate (PC) binders, for example. By way of example, the fiberpanel 128 may be constructed from about 50 percent natural fibers andabout 50 percent PP. To facilitate compression forming, the fiber panel128 is heated (e.g., to about 200 degrees Celsius) to induce thethermoplastic resin to liquefy. The fiber panel 128 is then disposedonto the first surface 122 of the cavity 124, and compressed between thefirst surface 122 and the second surface 126 as the second mold element120 is driven toward the first mold element 118 along the direction 130.As the fiber panel 128 cools within the mold assembly 116, thethermoplastic solidifies, thereby establishing a substantially rigidcomposite panel that conforms to the shape of the mold cavity 124.

In further embodiments, the fiber panel 128 includes a combination ofstructural fibers and a thermoset resin. Similar to the embodimentdescribed above, the structural fibers may include natural fibers, suchas hemp, wood, flax, kenaf and sisal, and/or synthetic fibers, such asglass fibers, carbon fibers and polymeric fibers. In addition, thethermoset resin may include epoxy resin, polyimide resin, polyesterresin and/or vinylester resin, for example. By way of example, the fiberpanel 128 may be constructed from Fibrowood, which is manufactured byJohnson Controls Technology Company of Holland, Mich. To facilitatecompression forming, the fiber panel 128 is disposed onto the firstsurface 122 of the cavity 124, and compressed between the first surface122 and the second surface 126 as the second mold element 120 is driventoward the first mold element 118 along the direction 130. During thecompression process, the panel 128 is heated (e.g., via a heated moldassembly 116), thereby inducing the thermoset resin to cure.Consequently, a substantially rigid composite panel that conforms to theshape of the mold cavity 124 is formed.

In the illustrated embodiment, the mold assembly 116 includes aretractable pin assembly 132 configured to hold the fiber panel 128 in adesired position until the second mold element 120 is proximate to thefirst mold element 118. As illustrated, the retractable pin assembly 132includes multiple holding pins 134 configured to penetrate the fiberpanel 128 to secure the fiber panel 128 to the first mold element 118.While the illustrated embodiment includes two holding pins 134, itshould be appreciated that alternative embodiments may include more orfewer holding pins 134. For example, certain embodiments may include 1,2, 3, 4, 6, 8, 10, 12, or more holding pins 134.

The retractable pin assembly 132 is configured to withdraw the holdingpins from the fiber panel 128 prior to or during compression of thefiber panel between the first surface 122 and the second surface 126.For example, the retractable pin assembly 132 may retract the holdingpins 134 when the first and second surfaces are sufficiently close tosubstantially block movement of the fiber panel 128 within the moldcavity 124. Because the holding pins 134 are withdrawn from the fiberpanel 128 prior to or during the compression forming process, resin maybe injected into voids formed by the holding pins 134, therebyestablishing a vehicle trim component having a substantially smoothsurface. In addition, because the holding pins 134 retract instead ofentering openings within the second mold element 120, the cost and/orcomplexity of the second mold element may be reduced.

In the illustrated embodiment, the retractable pin assembly 132 includesreturn pins 136 configured to drive the holding pins 134 to withdrawfrom the fiber panel 128. As discussed in detail below, contact betweenthe return pins 136 and a surface of the second mold element 120 drivesa connecting plate 138 away from the first surface 122. The connectingplate 138, in turn, drives the holding pins 134 to retract. The holdingpins 134 and the return pins 136 are coupled to the connecting plate 138by a suitable connection, such as a welded connection, a mechanicalinterlock, or a fastener, for example. While the illustrated embodimentincludes two return pins 136, it should be appreciated that alternativeembodiments may include more or fewer return pins 136. For example,certain embodiments may include 1, 2, 3, 4, 6, 8, 10, 12, or more returnpins.

The retractable pin assembly 132 also includes an actuator 140configured to extend the holding pins 134 after the mold elements areseparated from one another and the fiber panel is removed from the moldcavity. For example, the actuator 140 may include a pneumatic cylinderconfigured to drive the connecting plate 138 to an initial position thatenables the holding pins 134 to penetrate a subsequent fiber panel 128.However, it should be appreciated that the actuator 140 may include ahydraulic cylinder, an electromechanical drive unit, or a mechanicalactuator in alternative embodiments.

To secure the fiber panel 128 to the first mold element 118, the fiberpanel 128 is moved in the direction 142 such that a pointed end 144 ofeach holding pin 134 penetrates the fiber panel 128. For example, anoperator may position the fiber panel 128 at a desiredposition/orientation within the mold cavity 124, and then move the fiberpanel 128 in the direction 142 such that the holding pins 134 penetratethe fiber panel. Contact between the holding pins 134 and the fiberpanel 128 secures the fiber panel 128 in the desiredposition/orientation.

FIG. 13 is a schematic diagram of the mold assembly 116 of FIG. 12, inwhich the fiber panel 128 is secured to the first mold element 118 viathe holding pins 134. As previously discussed, the holding pins 134 areconfigured to secure the fiber panel 128 in a desiredposition/orientation until the first and second surfaces aresufficiently close to substantially block movement of the fiber panel128 within the mold cavity 124. Once the fiber panel 128 is secured tothe first mold element 118, the second mold element 120 is driven in thedirection 130. When the second mold element 120 is proximate to thefirst mold element 118, a distal end 146 of each return pin 136 contactsa bearing surface 148 of the second mold element 120. As the second moldelement 120 continues to move in the direction 130, contact between thebearing surface 148 and the distal end 146 of each return pin 136 drivesthe connecting plate 138 in the direction 150. Accordingly, the holdingpins 134 are driven in the direction 150, thereby withdrawing theholding pins 134 from the fiber panel 128. Because the holding pins 134are withdrawn while the mold elements are proximate to one another,movement of the fiber panel 128 is substantially blocked by the firstsurface 122 and the second surface 126.

As will be appreciated, the length of the holding pins 134 and/or thereturn pins 136 may be adjusted to control withdrawal of the holdingpins 134 from the fiber panel 128. For example, longer holding pins 134may secure the fiber panel 128 to the first mold element 118 until themold elements are closer to one another. Conversely, shorter holdingpins 134 may release the fiber panel 128 from the first mold element 118while the mold elements are farther apart. Similarly, longer return pins136 may induce the holding pins 134 to withdraw from the fiber panel 128while the mold elements are farther apart, and shorter return pins 136may induce the holding pins 134 to secure the fiber panel 128 to thefirst mold element 118 until the mold elements are closer to oneanother. As will be appreciated, controlling the withdrawal of theholding pins 134 may facilitate accurate placement of the fiber panelwithin the mold cavity, and may control tension within the fiber panelprior to or during the compression forming process.

FIG. 14 is a schematic diagram of the mold assembly of FIG. 12, in whichthe holding pins 134 are retracted. As previously discussed, contactbetween the distal end 146 of each return pin 136 and the bearingsurface 148 of the second mold element drives the return pins 136 in thedirection 150. Accordingly, the connecting plate 138, which is coupledto the return pins 136, drives the holding pins 134 in the direction150, thereby withdrawing the holding pins 134 from the fiber panel. Asillustrated, the holding pins 134 are withdrawn from the fiber panel128, and the fiber panel 128 is compressed between the first surface 122of the first mold element 118 and the second surface 126 of the secondmold element 120.

After the fiber panel is compression-formed into the desired shape, thesecond mold element 120 is driven in a direction 152 away from the firstmold element 118. The fiber panel 128 is then removed from the moldcavity 124 (e.g., via an ejection system). Next, the actuator 140 drivesthe connecting plate 138 in the direction 154, thereby transitioning theholding pins 134 and the return pins 136 to an extended position. Withthe holding pins 134 in the extended position, a subsequent fiber panel128 may be secured to the first mold element 118 via penetration of theholding pins 134 into the fiber panel 128.

While the embodiment described above employs an actuator to extend theholding pins 134 after the fiber panel 128 is removed from the moldcavity 124, it should be appreciated that other actuating assemblies maybe employed in alternative embodiments. For example, a mechanicallinkage between the second mold element and the holding pins may drivethe holding pins to extend as the second mold element moves away fromthe first mold element. In further embodiments, a spring may urge theholding pins to extend upon movement of the second mold element awayfrom the first mold element. Alternatively, the distal end of eachreturn pin may be magnetically coupled to the bearing surface of thesecond mold element. In such a configuration, movement of the secondmold element away from the first mold element drives the return pins andthe holding pins to the extended position. However, further movement ofthe second mold element away from the first mold element overcomes themagnetic coupling between the return pins and the second mold element,thereby enabling the second mold element to continue movement away fromthe first mold element. In further embodiments, the mold assembly mayinclude ejector pins to facilitate extraction of the fiber panel fromthe mold cavity. In such embodiments, movement of the ejector pins maydrive the connecting plate in the direction 154, thereby transitioningthe holding pins 134 to the extended position.

In addition, while the embodiment described above employs return pins136 and a connecting plate 138 to drive the holding pins 134 to retract,it should be appreciated that other actuating assemblies may be employedin alternative embodiments. For example, in certain embodiments, anactuator (e.g., hydraulic cylinder, pneumatic cylinder,electromechanical actuator, etc.) may be utilized to transition theholding pins between the extended and retracted positions. In suchembodiments, a sensor may be employed to determine a position of thesecond mold element relative to the first mold element. A controllercommunicatively coupled to the sensor may then control the position ofthe holding pins based on the detected position of the second moldelement. For example, the controller may instruct the holding pins toretract when the second mold element is proximate to the first moldelement. The controller may also instruct the holding pins to extend asthe second mold element moves away from the first mold element.

FIG. 15 is a schematic diagram of an embodiment of a mold assembly 116having a fluid pathway configured to inject resin into a void formed bya holding pin. As previously discussed, the fiber panel 128 is securedto the first mold element 118 by moving the fiber panel 128 in thedirection 142 such that the pointed end 144 of the holding pin 134penetrates the fiber panel 128. The second mold element 120 is thendriven in the direction 130, thereby inducing the retractable pinassembly 132 to withdraw the holding pin 134 from the fiber panel 128.However, the holding pin 134 may establish a void in the fiber panel128. Accordingly, the mold assembly 116 is configured to flow resin intothe void, thereby enhancing the smoothness of the vehicle trimcomponent.

In the illustrated embodiment, the first mold element 118 includes aresin manifold 156 and a fluid pathway 158 extending from the resinmanifold 156 to the retractable pin 134. As discussed in detail below,the resin manifold 156 and the fluid pathway 158 are configured toprovide resin to the void formed by the holding pin 134. As a result,the void may be filled with resin, thereby establishing a vehicle trimcomponent having a substantially smooth texture.

FIG. 16 is a schematic diagram of the mold assembly 116 of FIG. 15, inwhich the fiber panel 128 is secured to the first mold element 118 via aholding pin 134. As illustrated, the holding pin 134 displaces materialas the holding pin 134 penetrates the fiber panel 128. As a result, avoid is formed within the fiber panel 128. As discussed in detail below,the void may be filled with resin to establish a vehicle trim componenthaving a substantially smooth texture.

FIG. 17 is a schematic diagram of the mold assembly 116 of FIG. 15, inwhich the holding pin 134 is retracted. As illustrated, withdrawing theholding pin 134 from the fiber panel 128 forms a void 160. However, thefluid pathway 158 is positioned to flow resin from the resin manifold156 into the void 160. Accordingly, resin may be injected through themanifold 156 and the fluid pathway 158 to substantially fill the void160, thereby enhancing the smoothness of the vehicle trim component.

FIG. 18 is a schematic diagram of the mold assembly 116 of FIG. 15, inwhich resin is injected into the void 160 formed by the holding pin 134.As illustrated, the resin substantially fills the void 160, therebyforming a resin feature 162 that establishes a vehicle trim componenthaving a substantially smooth texture. In addition, the resinsubstantially fills the fluid pathway 158, thereby establishing a runneror ridge 164 on the rear surface of the vehicle trim component. As willbe appreciated, each void within the fiber panel may be filled in asimilar manner. Because the voids formed by the holding pins are filledwith resin, the holding pins may be positioned to provide enhancedcoupling between the fiber panel and the first mold element withoutdegrading the smoothness of the vehicle trim component.

FIG. 19 is a top view of an embodiment of a vehicle trim component 166formed within a mold cavity having a retractable pin assembly. Asillustrated, each void within the fiber panel 128 is filled with a resinfeature 162, thereby establishing a vehicle trim component 166 having asubstantially smooth surface. For example, a coverstock may be disposedon a surface of the fiber panel to form a desirable show surface.Because the voids in the fiber panel are filled with resin, thecoverstock may appear substantially smooth, thereby enhancing the visualappeal of the vehicle interior.

FIG. 20 is a flow diagram of an embodiment of a method 168 for forming avehicle trim component within a mold assembly having a retractable pinassembly. First, as represented by block 170, a fiber panel is securedto a first mold element via a retractable pin assembly. As previouslydiscussed, the retractable pin assembly includes multiple holding pinsconfigured to penetrate the fiber panel to secure the fiber panel to thefirst mold element. Next, as represented by block 172, the second moldelement is driven toward the first mold element. When the second moldelement is proximate to the first mold element, the holding pins of theretractable pin assembly are retracted, as represented by block 174. Forexample, the retractable pin assembly may include multiple return pinsconfigured to drive the holding pins to withdraw from the fiber panelvia contact between the return pins and the second mold element.

The fiber panel is then compressed between the first mold element andthe second mold element, as represented by block 176. As previouslydiscussed, compressing the fiber panel between the mold elements formsthe fiber panel into a desired shape. In certain embodiments, theholding pins are retracted (e.g., withdrawn from the fiber panel) as thefiber panel is compressed between the first mold element and the secondmold element. Resin is then injected into voids in the fiber panelformed by the holding pins, as represented by block 178. Filling thevoids may establish a vehicle interior component having a substantiallysmooth surface, thereby enhancing the appearance of the vehicleinterior.

After the compression forming/injection molding process is complete, thesecond mold element is driven away from the first mold element, asrepresented by block 180. The fiber panel is then ejected from the firstmold element (e.g., via ejection pins), as represented by block 182.Next, as represented by block 184, the holding pins of the retractablepin assembly are extended. For example, the retractable pin assembly mayinclude an actuator configured to drive the holding pins toward anextended position, thereby enabling the holding pins to penetrate asubsequent fiber panel.

Resin Feature for Supporting a Bent Edge of a Fiber Panel

Certain mold assemblies include a first mold element and a second moldelement configured to be brought together to compress a fiber panel intoa desired shape. Such mold assemblies may also include a trim bladeconfigured to penetrate the fiber panel as the first and second moldelements are brought together to trim the fiber panel to desireddimensions. Unfortunately, using an in-mold trim blade to shape thefiber panel may weaken the edges of the panel, thereby reducinglongevity.

Certain embodiments of the mold assembly described below are configuredto inject resin onto adjacent inner surfaces of a bent edge of the fiberpanel, thereby enhancing the strength of the edge. For example, incertain embodiments, a mold assembly for manufacturing a vehicle trimcomponent includes a first mold element configured to receive a fiberpanel. The mold assembly also includes a second mold element configuredto compress the fiber panel between a first surface of the first moldelement and a second surface of the second mold element to form thefiber panel into a desired shape. The mold assembly also includes afluid pathway configured to inject resin onto adjacent inner surfaces ofa bent edge of the fiber panel such that the resin extends to a distalend of the bent edge. Injecting the resin onto the inner surfaces of thebent edge establishes a resin feature that supports the bent edge,thereby enhancing the strength and increasing the longevity of the fiberpanel.

FIG. 21 is a schematic diagram of an embodiment of a mold assembly 186having a fluid pathway configured to inject resin onto adjacent innersurfaces of a bent edge of a fiber panel. In the illustrated embodiment,the mold assembly 186 includes a first (e.g., lower) mold element 188and a second (e.g., upper) mold element 190. As illustrated, the firstmold element 188 includes a first surface 192 defining a first portionof a mold cavity 194, and the second mold element 190 includes a secondsurface 196 defining a second portion of the mold cavity 194. The firstsurface 192 is configured to receive a fiber panel 198, and the secondsurface 196 is configured to compress the fiber panel 198 against thefirst surface 192 to form the fiber panel 198 into a desired shape.

In certain embodiments, the fiber panel 198 includes a combination ofstructural fibers and thermoplastic resin. The structural fibers mayinclude natural fibers, such as hemp, wood, flax, kenaf and sisal,and/or synthetic fibers, such as glass fibers, carbon fibers andpolymeric fibers. In addition, the thermoplastic resin may includepolypropylene (PP), acrylonitrile butadiene styrene (ABS) and/orpolycarbonate (PC) binders, for example. By way of example, the fiberpanel 198 may be constructed from about 50 percent natural fibers andabout 50 percent PP. To facilitate compression forming, the fiber panel198 is heated (e.g., to about 200 degrees Celsius) to induce thethermoplastic resin to liquefy. The fiber panel 198 is then disposedonto the first surface 192 of the cavity 194, and compressed between thefirst surface 192 and the second surface 196 as the second mold element190 is driven toward the first mold element 188 along the direction 200.As the fiber panel 198 cools within the mold assembly 186, thethermoplastic solidifies, thereby establishing a substantially rigidcomposite panel that conforms to the shape of the mold cavity 194.

In further embodiments, the fiber panel 198 includes a combination ofstructural fibers and a thermoset resin. Similar to the embodimentdescribed above, the structural fibers may include natural fibers, suchas hemp, wood, flax, kenaf and sisal, and/or synthetic fibers, such asglass fibers, carbon fibers and polymeric fibers. In addition, thethermoset resin may include epoxy resin, polyimide resin, polyesterresin and/or vinylester resin, for example. By way of example, the fiberpanel 198 may be constructed from Fibrowood, which is manufactured byJohnson Controls Technology Company of Holland, Mich. To facilitatecompression forming, the fiber panel 198 is disposed onto the firstsurface 192 of the cavity 194, and compressed between the first surface192 and the second surface 196 as the second mold element 190 is driventoward the first mold element 188 along the direction 200. During thecompression process, the panel 198 is heated (e.g., via a heated moldassembly 186), thereby inducing the thermoset resin to cure.Consequently, a substantially rigid composite panel that conforms to theshape of the mold cavity 194 is formed.

In the illustrated embodiment, the first mold element 188 includes trimblades 202 configured to trim the fiber panel 198 to desired dimensionsas the fiber panel 198 is compressed within the mold cavity 194. As thesecond mold element 190 is driven in the direction 200, contact betweenthe second mold element 190 and the fiber panel 198 drives edges of thefiber panel 198 into contact with the trim blades 202. Further movementof the second mold element 190 in the direction 200 induces the trimblades 202 to penetrate the fiber panel 198, thereby trimming the fiberpanel 198 to the desired dimensions. While two trim blades 202 areemployed in the illustrated embodiment, it should be appreciated thatalternative embodiments may include more or fewer trim blades 202 (e.g.,1, 2, 3, 4, 5, 6, or more). Furthermore, while the trim blades 202 arecoupled to the first mold element 188 in the illustrated embodiment, itshould be appreciated that at least a portion of the trim blades 202 maybe coupled to the second mold element 190 in alternative embodiments.

The process of trimming the fiber panel 198 with the trim blades 202 mayweaken the edges of the fiber panel 198. Accordingly, the illustratedmold assembly 186 is configured to inject resin onto adjacent innersurfaces of a bent edge of the fiber panel 198, thereby enhancing thestrength of the edge. As illustrated, the second mold element 190includes a recess 204 configured to establish a void within the moldcavity 194 when the mold assembly 186 is closed. As discussed in detailbelow, when the mold assembly 186 is closed, the void is positionedproximate to adjacent inner surfaces of a bent edge of the fiber panel198. In the illustrated embodiment, the second mold element includes aninlet 206 and a fluid pathway 208 extending from the inlet 206 to thevoid. The fluid pathway 208 is configured to inject the resin into thevoid such that the resin flows onto adjacent inner surfaces of a bentedge of the fiber panel.

FIG. 22 is a schematic diagram of the mold assembly 186 of FIG. 21 in aclosed position. With the mold assembly in the closed position, the trimblade 202 penetrates the fiber panel 198, thereby trimming the fiberpanel to the desired dimensions. In addition, the recess 204 establishesa void 210 positioned proximate to adjacent inner surfaces of a bentedge of the fiber panel 198. When resin is injected into the void 210(e.g., via the inlet 206 and the fluid pathway 208), the resin flowsonto the adjacent inner surfaces of the bent edge. Because the voidextends to a distal end of the bent edge, the resin flows to the lateralextent of the fiber panel 198 (e.g., where the trim blade 202 cuts thefiber panel 198). Once the resin cures and hardens, a resin feature isformed that supports the bent edge of the fiber panel, thereby enhancingthe strength and increasing the longevity of the vehicle trim component.In certain embodiments, the void 210 may extend about the entireperiphery of the fiber panel 198. However, in alternative embodiments,the void 210 may extend about a portion of the periphery.

FIG. 23 is a cross-sectional view of an embodiment of a vehicle trimcomponent 212 having a resin feature 214 configured to support a bentedge of the fiber panel 198. As illustrated, the resin feature 214 isinjection-molded (e.g., via the mold assembly 186 having the void 210)onto an inner surface 216 of the fiber panel 198. When the trimcomponent 212 is installed within a vehicle, the inner surface 216 facesaway from the vehicle interior. In this configuration, the resin feature214 supports the bent edge 218 of the fiber panel 198 while providing asubstantially smooth show surface (e.g., the surface opposite the innersurface 216).

In the illustrated embodiment, the resin feature 214 extends between afirst inner surface 220 of the bent edge 218 and a second inner surface222 of the bent edge 218. In addition, the resin feature 214 extends toa distal end of the bent edge 218. Accordingly, the resin feature 214supports the bent edge 218, thereby enhancing the strength of the fiberpanel 198, and increasing the longevity of the vehicle trim component212. As will be appreciated, a length 224 of the fiber panel 198 may beselected based on a desired application. In addition, a length 226 ofthe resin feature 214 may be particularly selected to provide desiredsupport to the bent edge 218 of the fiber panel 198. For example, if thevehicle trim component 212 is employed within a door panel, the resinfeature 214 may have a longer length 226 to accommodate expected loads(e.g., from an occupant pulling on the bent edge 218 to close a vehicledoor, from service personnel prying the bent edge 218 away from the doorto remove the door panel, etc.). Furthermore, a height 228 of the bentedge 218 and a height 230 of the resin feature 214 may be particularlyselected to provide desired support to the bent edge 218. For example,longer heights 228 and 230 may enhance the strength of the edge, therebyenabling the vehicle trim component 212 to accommodate higher loads.

In certain embodiments, the resin feature 214 may extend about theentire periphery of the vehicle trim component 212. However, alternativeembodiments may include a resin feature 214 that extends about a portionof the periphery. In addition, while an angle between the inner surfaces220 and 222 of the bent edge 218 is about 90 degrees in the illustratedembodiment, it should be appreciated that alternative embodiments mayinclude a larger or smaller angle between the inner surfaces. In furtherembodiments, the bent edge may be curved, or may include multiple angledsections.

FIG. 24 is a flow diagram of an embodiment of a method 232 for forming avehicle trim component by injecting resin onto adjacent inner surfacesof a bent edge of a fiber panel. First, the fiber panel is heated, asrepresented by block 234. For example, if the fiber panel includesthermoplastic resin, heating the panel liquefies the resin, therebyfacilitating compression forming of the panel. Alternatively, if thefiber panel includes a thermoset resin, the panel may be heated duringthe compression process. The fiber panel is then disposed onto a firstsurface of a mold cavity, as represented by block 236. Next, the fiberpanel is compressed between the first surface and a second surface ofthe mold cavity to form the fiber panel into a desired shape, asrepresented by block 238.

Resin is then injected onto adjacent inner surfaces of a bent edge ofthe fiber panel, as represented by block 240. For example, the resin maybe injected into a void positioned proximate to the adjacent innersurfaces of the bent edge. In such a configuration, the void establishesa resin feature that supports the bent edge of the fiber panel, therebyincreasing the strength of the panel. After the interior trim componentis removed from the mold cavity, a cover stock may be disposed onto thevehicle trim component, as represented by block 242. In certainembodiments, the fiber panel and/or various resin components may beparticularly configured to provide a desirable show surface for the trimcomponent. In such embodiments, the cover stock may be obviated, therebyreducing manufacturing costs.

Floating Core Assembly for Urging a Fiber Panel Against a Mold Surface

Certain mold assemblies include a first mold element and a second moldelement configured to be brought together to compress a fiber panel intoa desired shape. For example, the second mold element may drive thefiber panel into contact with the first mold element. Further movementof the second mold element relative to the first mold element compressesthe fiber panel into the desired shape. In addition, a trim blade may becoupled to the first mold element, and configured to trim the fiberpanel to desired dimensions as the first and second mold elementscompress the fiber panel. Unfortunately, as the second mold elementdrives the fiber panel into contact with the first mold element, thefiber panel may become caught on the trim blade. As a result, the trimblade may tear a portion of the fiber panel, thereby weakening the fiberpanel, and/or forming a vehicle trim component having an undesirableappearance/texture. In addition, while the fiber panel is caught on thetrim blade, tension may build within the fiber panel as the second moldelement continues to move toward the first mold element. Once the fiberpanel is freed from the trim blade, the released tension may drive thefiber panel to shift within the mold assembly, thereby shifting thefiber panel away from the desired position/orientation.

Certain embodiments of the mold assembly described below include afloating core assembly configured to urge the fiber panel against asurface of a mold element before a trim blade penetrates the fiberpanel. For example, in certain embodiments, a mold assembly formanufacturing a vehicle trim component includes a first mold element anda second mold element configured to be brought together to compress afiber panel into a desired shape. The mold assembly also includes a trimblade configured to penetrate the fiber panel as the first and secondmold elements are brought together to trim the fiber panel to desireddimensions. The mold assembly also includes a floating core assemblycoupled to the second mold element, and configured to urge the fiberpanel against a surface of the first mold element before the trim bladepenetrates the fiber panel. Because the fiber panel is disposed againstthe surface of the first mold element before the trim blade penetratesthe fiber panel, the possibility of the fiber panel being caught on thetrim blade is substantially reduced or eliminated. Accordingly, the moldassembly may form a stronger and/or more aesthetically pleasing trimcomponent.

FIG. 25 is a schematic diagram of an embodiment of a mold assembly 244having a floating core assembly configured to urge a fiber panel againsta surface of a mold element. In the illustrated embodiment, the moldassembly 244 includes a first (e.g., lower) mold element 246 and asecond (e.g., upper) mold element 248. As illustrated, the first moldelement 246 includes a first surface 250 defining a first portion of amold cavity 252, and the second mold element 248 includes a secondsurface 254 defining a second portion of the mold cavity 252. The firstsurface 250 is configured to receive a fiber panel 256, and the secondsurface 254 is configured to compress the fiber panel 256 against thefirst surface 250 to form the fiber panel 256 into a desired shape.

In the illustrated embodiment, the second mold element 248 includes afloating core assembly 260 having a core 262 and biasing members 264(e.g., springs). As illustrated, the second surface 254 of the secondmold element 248 is formed by the core 262 of the floating core assembly260. Prior to compressing the fiber panel 256 within the mold cavity252, the core 262 urges the fiber panel against the first surface 250 ofthe first mold element 246 as the second mold element 248 moves in thedirection 258. Once the second surface 254 is in contact with the fiberpanel 256, and the fiber panel 256 is in contact with the first surface250, further movement of the second mold element 248 in the direction258 induces the core to transition from the illustrated extendedposition to a retracted position. With the core 262 in the retractedposition, the biasing members 264 provide sufficient force to compressthe fiber panel 256 within the mold cavity 252.

In certain embodiments, the fiber panel 256 includes a combination ofstructural fibers and thermoplastic resin. The structural fibers mayinclude natural fibers, such as hemp, wood, flax, kenaf and sisal,and/or synthetic fibers, such as glass fibers, carbon fibers andpolymeric fibers. In addition, the thermoplastic resin may includepolypropylene (PP), acrylonitrile butadiene styrene (ABS) and/orpolycarbonate (PC) binders, for example. By way of example, the fiberpanel 256 may be constructed from about 50 percent natural fibers andabout 50 percent PP. To facilitate compression forming, the fiber panel256 is heated (e.g., to about 200 degrees Celsius) to induce thethermoplastic resin to liquefy. The fiber panel 256 is then urgedagainst the first surface 250 of the cavity 252, and compressed betweenthe first surface 250 and the second surface 254 as the second moldelement 248 is driven toward the first mold element 246 along thedirection 258. As the fiber panel 256 cools within the mold assembly244, the thermoplastic solidifies, thereby establishing a substantiallyrigid composite panel that conforms to the shape of the mold cavity 252.

In further embodiments, the fiber panel 256 includes a combination ofstructural fibers and a thermoset resin. Similar to the embodimentdescribed above, the structural fibers may include natural fibers, suchas hemp, wood, flax, kenaf and sisal, and/or synthetic fibers, such asglass fibers, carbon fibers and polymeric fibers. In addition, thethermoset resin may include epoxy resin, polyimide resin, polyesterresin and/or vinylester resin, for example. By way of example, the fiberpanel 256 may be constructed from Fibrowood, which is manufactured byJohnson Controls Technology Company of Holland, Mich. To facilitatecompression forming, the fiber panel 256 is urged against the firstsurface 250 of the cavity 252, and compressed between the first surface250 and the second surface 254 as the second mold element 248 is driventoward the first mold element 246 along the direction 258. During thecompression process, the panel 256 is heated (e.g., via a heated moldassembly 244), thereby inducing the thermoset resin to cure.Consequently, a substantially rigid composite panel that conforms to theshape of the mold cavity 252 is formed.

In the illustrated embodiment, the first mold element 246 includes trimblades 266 configured to trim the fiber panel 256 to desired dimensionsas the fiber panel 256 is compressed within the mold cavity 252. Aspreviously discussed, movement of the second mold element 248 in thedirection 258 induces the core 262 to retract upon contact between thecore 262, the fiber panel 256, and the first surface 250. As the core262 retracts, a body of the second mold element 248 continues to move inthe direction 258. Contact between the body of the second mold element248 and the fiber panel 256 drives edges of the fiber panel 256 intocontact with the trim blades 266. Further movement of the second moldelement 248 in the direction 258 induces the trim blades 266 topenetrate the fiber panel 256, thereby trimming the fiber panel 256 tothe desired dimensions. While two trim blades 266 are employed in theillustrated embodiment, it should be appreciated that alternativeembodiments may include more or fewer trim blades 266 (e.g., 1, 2, 3, 4,5, 6, or more). Furthermore, while the trim blades 266 are coupled tothe first mold element 246 in the illustrated embodiment, it should beappreciated that at least a portion of the trim blades 266 may becoupled to the second mold element 248 in alternative embodiments.Because the fiber panel is disposed against the first surface 250 of thefirst mold element 246 before the trim blades 266 penetrate the fiberpanel 256, the possibility of the fiber panel being caught on the trimblades 266 is substantially reduced or eliminated. Accordingly, thefiber panel 256 may remain substantially smooth and properlyoriented/positioned during the forming process, thereby establishing astrong and/or aesthetically pleasing trim component.

FIG. 26 is a schematic diagram of the mold assembly 244 of FIG. 25, inwhich the core 262 of the floating core assembly 260 is in an extendedposition, and the fiber panel 256 is disposed against the first surface250 of the first mold element 246. As previously discussed, movement ofthe second mold element 248 in the direction 258 drives the core 262 tourge the fiber panel 256 against the first surface 250 of the first moldelement 246. Once the second surface 254 is in contact with the fiberpanel 256, and the fiber panel 256 is in contact with the first surface250, further movement of the second mold element 248 in the direction258 induces the core 262 to move in the direction 268 toward theretracted position. As the core 262 retracts, the biasing members 264are compressed, thereby increasing the force applied to the core 262. Incertain embodiments, the force applied by the compressed biasing members264 is sufficient to compress the fiber panel 256 into a desired shapedwithin the mold cavity 252. In addition, as the body of the second moldelement is driven in the direction 258, contact between the body and thefiber panel 256 drives edges of the fiber panel 256 into contact withthe trim blades 266. Further movement of the second mold element 248 inthe direction 258 induces the trim blades 266 to penetrate the fiberpanel 256, thereby trimming the fiber panel 256 to the desireddimensions.

FIG. 27 is a schematic diagram of the mold assembly 244 of FIG. 25, inwhich the core 262 of the floating core assembly 260 is in a retractedposition. With the core 262 in the retracted position, the compressedbiasing members 264 urge the core 262 toward the first surface 250 ofthe first mold element 246 with sufficient force to compress the fiberpanel 256 into a desired shape. In addition, a bearing surface 270 ofthe second mold element 248 drive the fiber panel 256 toward the firstmold element 246 such that the trim blades 266 penetrated the fiberpanel 256, and trim the fiber panel 256 to the desired dimensions.Because the fiber panel is disposed against the first surface 250 of thefirst mold element 246 before the trim blades 266 penetrate the fiberpanel 256, the possibility of the fiber panel being caught on the trimblades 266 is substantially reduced or eliminated. Accordingly, thefiber panel 256 may remain substantially smooth and properlyoriented/positioned during the forming process, thereby establishing astrong and/or aesthetically pleasing trim component.

While only certain features and embodiments of the invention have beenillustrated and described, many modifications and changes may occur tothose skilled in the art (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters (e.g., temperatures, pressures, etc.), mounting arrangements,use of materials, colors, orientations, etc.) without materiallydeparting from the novel teachings and advantages of the subject matterrecited in the claims. The order or sequence of any process or methodsteps may be varied or re-sequenced according to alternativeembodiments. It is, therefore, to be understood that the appended claimsare intended to cover all such modifications and changes as fall withinthe true spirit of the invention. Furthermore, in an effort to provide aconcise description of the exemplary embodiments, all features of anactual implementation may not have been described (i.e., those unrelatedto the presently contemplated best mode of carrying out the invention,or those unrelated to enabling the claimed invention). It should beappreciated that in the development of any such actual implementation,as in any engineering or design project, numerous implementationspecific decisions may be made. Such a development effort might becomplex and time consuming, but would nevertheless be a routineundertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure, without undueexperimentation.

The invention claimed is:
 1. A mold assembly for manufacturing a vehicletrim component, comprising: a first mold element configured to receive afiber panel; a retractable pin assembly comprising a plurality ofholding pins configured to penetrate the fiber panel to secure the fiberpanel to the first mold element; a second mold element configured tocompress the fiber panel between a first surface of the first moldelement and a second surface of the second mold element to form thefiber panel into a desired shape, wherein the retractable pin assemblyis configured to withdraw the plurality of holding pins from the fiberpanel prior to or during compression of the fiber panel between thefirst and second surfaces; and a fluid pathway configured to injectresin into a void in the fiber panel formed by one of the plurality ofholding pins, wherein at least a portion of the fluid pathway is alignedwith the void.
 2. The mold assembly of claim 1, wherein the retractablepin assembly comprises a plurality of return pins configured to drivethe plurality of holding pins to withdraw from the fiber panel viacontact between the plurality of return pins and the second moldelement.
 3. The mold assembly of claim 2, wherein the plurality ofholding pins and the plurality of return pins are coupled to one anotherby a connecting plate.
 4. The mold assembly of claim 1, wherein theretractable pin assembly comprises an actuator configured to extend theplurality of holding pins to facilitate penetration of the holding pinsinto the fiber panel.
 5. The mold assembly of claim 1, wherein the resinis configured to form a resin feature that enhances a smoothness of thevehicle trim component.
 6. The mold assembly of claim 1, wherein theretractable pin assembly is configured to withdraw the plurality ofholding pins from the fiber panel when the first and second surfaces aresufficiently close to substantially block movement of the fiber panelrelative to the first and second mold elements.
 7. A mold assembly formanufacturing a vehicle trim component, comprising: a first mold elementconfigured to receive a fiber panel; a retractable pin assemblycomprising a plurality of holding pins configured to penetrate the fiberpanel to secure the fiber panel to the first mold element; and a secondmold element configured to compress the fiber panel between a firstsurface of the first mold element and a second surface of the secondmold element to form the fiber panel into a desired shape, wherein thedesired shape substantially corresponds to a first contour of the firstsurface and a second contour of the second surface, and the desiredshape is different than an original shape of the fiber panel; whereinthe retractable pin assembly is configured to withdraw the plurality ofholding pins from the fiber panel prior to or during compression of thefiber panel between the first and second surfaces.
 8. The mold assemblyof claim 7, wherein the retractable pin assembly comprises a pluralityof return pins configured to drive the plurality of holding pins towithdraw from the fiber panel via contact between the plurality ofreturn pins and the second mold element.
 9. The mold assembly of claim8, wherein the plurality of holding pins and the plurality of returnpins are coupled to one another by a connecting plate.
 10. The moldassembly of claim 7, wherein the retractable pin assembly comprises anactuator configured to extend the plurality of holding pins tofacilitate penetration of the holding pins into the fiber panel.
 11. Themold assembly of claim 7, comprising a fluid pathway configured toinject resin into a void in the fiber panel formed by one of theplurality of holding pins.
 12. The mold assembly of claim 11, whereinthe resin is configured to form a resin feature that enhances asmoothness of the vehicle trim component.
 13. The mold assembly of claim7, wherein the retractable pin assembly is configured to withdraw theplurality of holding pins from the fiber panel when the first and secondsurfaces are sufficiently close to substantially block movement of thefiber panel relative to the first and second mold elements.